Bracket for connection of a junction box to photovoltaic panels

ABSTRACT

A device for attaching a junction box to a photovoltaic. The photovoltaic panel has a photovoltaic side and a non-photovoltaic side. The device includes a bracket with a first side attachable to the junction box and a second side attachable to the non-photovoltaic surface of the photovoltaic panel. A central fastener is attachable at one end to the bracket and a plate is adapted for connecting to the other end of the central fastener and for mounting on the photovoltaic side of the photovoltaic panel. One or more rotatable spacers, connectible to the central fastener, may be located on the non-photovoltaic side of the photovoltaic panel. One or more fixed spacers may be located on the non-photovoltaic side connectible to the bracket.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No. 12/786,894, filed May 25, 2010, which claims benefit from U.S. patent application 61/180,912 filed May 25, 2009, the disclosures of which are incorporated herein by reference.

BACKGROUND

1. Technical Field

The present invention relates to attaching junction boxes to photovoltaic panels and specifically to a bracket for attaching junction boxes to photovoltaic panels.

2. Description of Related Art

A photovoltaic module or photovoltaic panel is a packaged interconnected assembly of photovoltaic cells, also known as solar cells. Since a single photovoltaic module can only produce a limited amount of power, commercial installations include several modules or panels interconnected in serial and in parallel into a photovoltaic array. Electrical connections are made in series to achieve a desired output voltage and/or in parallel to provide a desired amount of current source capability. A photovoltaic installation typically includes the array of photovoltaic modules, an inverter, batteries and interconnection wiring. Electronic modules may be integrated with the photovoltaic modules which perform electrical conversion, e.g. direct current (DC) to direct current conversion, electrical inversion, e.g. micro-inverter, or other functions such as monitoring of performance and/or protection against theft.

An approach for mounting photovoltaic modules on the roofs of buildings is disclosed in U.S. Pat. No. 7,435,897, which discloses attaching a junction box to a bracket as part of a photovoltaic installation.

The term “cable gland” as used herein refers to a device used for the entry of electrical cables or cords into electrical equipment and is used to firmly secure an electrical cable entering a piece of electrical equipment.

The terms “bracket”, “mount” and “bracket mount” are used herein interchangeably.

The terms “central fastener” and “central pillar” are used herein interchangeably.

BRIEF SUMMARY

According to an aspect of the present invention there is provided a device for attaching a junction box to a photovoltaic panel, the photovoltaic panel having a photovoltaic side and a non-photovoltaic side. The device includes a bracket with a first side attachable to the junction box and a second side attachable to the non-photovoltaic surface of the photovoltaic panel. A central fastener is attachable at one end to the bracket and a plate is adapted for connecting to the other end of the central fastener and for mounting on the photovoltaic panel or frame typically on the photovoltaic side of the panel. One or more rotatable spacers, connectible to the central fastener, may be located on the non-photovoltaic side of the photovoltaic panel. One or more fixed spacers may be located on the non-photovoltaic side connectible to the bracket.

The bracket may attach to respective non-photovoltaic sides of two adjacent photovoltaic panels and the central fastener extends between respective edges of the two adjacent photovoltaic panels. The two adjacent panels are electrically connectible within the junction box. The bracket may also attach to respective non-photovoltaic sides of four adjacent photovoltaic panels, with the central fastener extending between respective corners of the four adjacent photovoltaic panels. The four adjacent panels are typically connected electrically within the junction box.

According to another aspect of the present invention, there is provided a method for attaching a junction box to one or more photovoltaic panels. The photovoltaic panel has a photovoltaic side and a non-photovoltaic side. A first side of a bracket is attached to the junction box and a second side of the bracket is attached to the non-photovoltaic side. A central fastener is attached at one end to the bracket. A plate usually rotatable is connected to the other end of the central fastener and mounted on the photovoltaic side of the photovoltaic panel. One or more spacers are optionally rotatable and connected on the non-photovoltaic side to the central fastener. The bracket may be attached to non-photovoltaic sides of two adjacent photovoltaic panels and the central fastener extends between respective edges of two adjacent photovoltaic panels. The two adjacent photovoltaic panels may be electrically connected within the junction box. Alternatively, the bracket is attached to non-photovoltaic sides of four adjacent photovoltaic panels, and the central fastener extends between respective corners of the four adjacent photovoltaic panels. The four adjacent photovoltaic panels may be connected within the junction box.

These, additional, and/or other aspects and/or advantages of the present invention are: set forth in the detailed description which follows; possibly inferable from the detailed description; and/or learnable by practice of the present invention.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention is herein described, by way of example only, with reference to the accompanying drawings, wherein:

FIG. 1 a shows a junction box mechanically attached to two photovoltaic panels by a bracket according to an aspect of the present invention.

FIG. 1 b shows two junction boxes, which may be mounted (using a bracket) in various positions on multiple panels, according to an aspect of the present invention.

FIG. 1 c shows a topside plan view of a bracket mount according to an aspect of the present invention.

FIG. 1 d shows a side view of a bracket mount according to an aspect of the present invention.

FIG. 1 e shows a bottom side plan view of a bracket mount according to an aspect of the present invention.

FIG. 1 f shows an isometric view looking at the topside of a bracket mount according to an aspect of the present invention.

FIG. 1 g shows an isometric view looking at the bottom side of a bracket mount according to an aspect of the present invention.

FIG. 2 a shows a topside plan view of a bracket mount mounted to a junction box according to an aspect of the present invention.

FIG. 2 b shows a side view of a bracket mount mounted to a junction box according to an aspect of the present invention.

FIG. 3 a shows the photovoltaic side of two solar panels with a bracket mount and a junction box attached in between the two solar panels according to an aspect of the present invention.

FIG. 3 b shows further details of a bracket mount and a junction box attached in between two solar panels according to an aspect of the present invention.

FIG. 4 shows a flow diagram illustrating a method according to features of the present invention for attaching a junction box to one or more photovoltaic panels.

The foregoing and/or other aspects will become apparent from the following detailed description when considered in conjunction with the accompanying drawing figures.

DETAILED DESCRIPTION

Reference will now be made in detail to embodiments of the present invention, examples of which are illustrated in the accompanying drawings, wherein like reference numerals refer to the like elements throughout. The aspects are described below to explain the present invention by referring to the figures.

Before explaining aspects of the invention in detail, it is to be understood that the invention is not limited in its application to the details of design and the arrangement of the components set forth in the following description or illustrated in the drawings. The invention is capable of other aspects or of being practiced or carried out in various ways. Also, it is to be understood that the phraseology and terminology employed herein is for the purpose of description and should not be regarded as limiting.

Reference is now made to FIG. 1 a which shows a junction box 200 mechanically attached to two photovoltaic panels 300 b and 300 a respectively by a bracket 10 according to an aspect of the present invention. Junction box 200 is typically mounted on the non photovoltaic sides of panels 300 a and 300 b. Junction box 200 may typically contain a circuit board and connection terminals which are both used to terminate cables entering and leaving junction box 200 using cable glands 14, male socket connectors 12 a and female socket connectors 12 b. Junction box 200 typically provides a way for connecting panels 300 a and 300 b electrically together. The junction box may be passive including connector and wires, and possibly passive elements such as diodes, or active—e.g. containing a circuit board inside that implements a direct current (DC) to alternating current (AC) inverter or a DC to DC converter. Junction box 200 is attached to a bracket or mount 10 and bracket 10 is used to attach junction box 200 to photovoltaic panels 300 a and 300 b.

Reference is now made to FIG. 1 b which shows junction boxes 200 a and 200 b, which may be mounted (using bracket 10) in various positions on multiple panels 300 a, 300 b, 300 c or 300 d, according to an aspect of the present invention. Junction box 200 a may be used to connect panels 300 a and 300 b electrically together. Alternatively, junction box 200 b shown located near cross point 666 or at cross point 666 of panels 300 may be used to connect panels 300 a, 300 b, 300 c or 300 d electrically together.

Reference is now made to FIGS. 1 c, 1 d and 1 e which show top side plan view, a side view and a bottom side plan view respectively of a bracket mount 10 according to an aspect of the present invention. Bracket mount 10 has a four mounting holes 102 used to secure bracket mount 10 to junction box 200. Bracket 10 also has two fixed positioned spacers 110 which are preferably spring loaded and two adjustable position spacers 108 which are also preferably spring loaded. Plate 106 swivels around a central pillar 104 such that plate 106 is parallel to the X Y plane shown in FIG. 1 e.

Reference is now made to FIGS. 1 f and 1 g which show an isometric views looking at the topside and bottom side of bracket 10 according to an aspect of the present invention. FIGS. 1 f and 1 g show the four mounting holes 102, two fixed positioned spacers 110, the two adjustable position spacers 108, plate 106 and central pillar 104.

Reference is now made to FIGS. 2 a and 2 b which show a plan view 20 and side view 22 of bracket mount 10 attached to junction box 200 via four mounting holes 102 according to an aspect of the present invention. FIGS. 2 a and 2 b show the two fixed positioned spacers 110, the two adjustable position spacers 108, plate 106, central pillar 104, bracket mount 10 and junction box 200 along with cable glands 14, male socket connectors 12 a and female socket connectors 12 b.

Reference is now made to FIGS. 3 a and 3 b which show an isometric view 30 and isometric view of area 32 respectively according to an aspect of the present invention. FIG. 3 a shows the photovoltaic side of two solar panels 300 a and 300 b with bracket mount 10 (attached to junction box 200) attached in between two solar panels 300 a and 300 b (shown by area 32). FIG. 3 b shows further details of the isometric view of area 32. With bracket mount 10 attached to junction box 200, bracket mount 10 and junction box 200 are located on the non-photovoltaic side of solar panels 300 a and 300 b. Central pillar 104 protrudes between solar panels 300 a and 300 b with plate 106 twisted around central pillar 104 so that plate 106 is in contact with the photovoltaic side of panels 300 a and 300 b. The two fixed positioned spring loaded spacers 110 and the two adjustable spring loaded position spacers 108 (shown with a dotted line) allow bracket 10 (attached to junction box 200) to clamp onto panels 300 a and 300 b. Through a gap between panels 300 a and 300 b can be seen fixed positioned spacers 110 and a male socket connector 12 a.

Reference is now also made to FIG. 4, a flow diagram illustrating a method according to features of the present invention for attaching junction box 200 to one or more photovoltaic panels 300. A first side of bracket 10 is attached (step 41) to junction box 200 and a second side of bracket 10 is attached (step 41) to the non-photovoltaic side. A central fastener 104 is attached (step 43) at one end to bracket 10. Bracket 10 may be previously assembled with the fastener 104, and the installer only mounts the junction box 200 to bracket 10, and then mount bracket 10 to panel 300 Plate 106 is rotatably connected (step 45) to the other end of the central fastener 104 and mounted on the photovoltaic side of photovoltaic panel 300. One or more rotatable spacers 108 are connected on the non-photovoltaic side to the central fastener. Bracket 10 may be attached to non-photovoltaic sides of two adjacent photovoltaic panels 300 and central fastener 104 extends between respective edges of two adjacent photovoltaic panels 300. The two adjacent photovoltaic panels 300 may be electrically connected within junction box 200. Alternatively, bracket 10 is attached to non-photovoltaic sides of four adjacent photovoltaic panels 300, and central fastener 104 extends between respective corners of the four adjacent photovoltaic panels 300. The four adjacent photovoltaic panels 300 may be connected within junction box 200.

The definite articles “a”, “an” is used herein, such as “a bracket”, “a junction box” have the meaning of “one or more” that is “one or more brackets” or “one or junction boxes”.

Examples of various features/aspects/components/operations have been provided to facilitate understanding of the disclosed embodiments of the present invention. In addition, various preferences have been discussed to facilitate understanding of the disclosed embodiments of the present invention. It is to be understood that all examples and preferences disclosed herein are intended to be non-limiting.

Although selected embodiments of the present invention have been shown and described individually, it is to be understood that at least aspects of the described embodiments may be combined. Also although selected embodiments of the present invention have been shown and described, it is to be understood the present invention is not limited to the described embodiments. Instead, it is to be appreciated that changes may be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the claims and the equivalents thereof. 

We claim:
 1. A device comprising: a junction box; a plate; a central fastener connecting the junction box to the plate, the central fastener adapted to attach the device to a photovoltaic panel by clamping the photovoltaic panel between the junction box and the plate; and at least one adjustable spacer adapted to be mounted and adjustable in position in a space between the junction box and the photovoltaic panel.
 2. The device of claim 1, wherein the junction box is adapted to attach to a non-photovoltaic side of the photovoltaic panel and the plate is adapted to attach to a photovoltaic side of the photovoltaic panel.
 3. The device of claim 1, wherein the at least one adjustable spacer is spring loaded.
 4. The device of claim 1, wherein the at least one adjustable spacer is rotatable around the central fastener.
 5. The device of claim 1, further comprising: at least one fixed spacer adapted to be fixed in position in the space between the junction box and the photovoltaic panel.
 6. The device of claim 1, further comprising one or more connectors adapted to receive electrical power generated by the photovoltaic panel.
 7. The device of claim 1, wherein the central fastener is further adapted to attach the device to a second photovoltaic panel by clamping the second photovoltaic panel between the junction box and the plate.
 8. The device of claim 7, wherein the central fastener is adapted to extend between an edge of the photovoltaic panel and an adjacent edge of the second photovoltaic panel.
 9. The device of claim 7, further comprising one or more connectors mounted on the junction box and adapted to electrically connect the photovoltaic panel to the second photovoltaic panel.
 10. The device of claim 1, wherein the central fastener is further adapted to attach the device to second, third, and fourth photovoltaic panels by clamping the second, the third, and the fourth photovoltaic panels between the junction box and the plate.
 11. The device of claim 1, wherein the plate is rotatably connected to the central fastener.
 12. The device of claim 1, further comprising a direct-current-to-direct-current converter or a direct-current-to-alternating-current converter within the junction box.
 13. The device of claim 1, further comprising a bracket connecting the junction box to the central fastener.
 14. A method comprising: mounting a junction box to a photovoltaic panel by clamping the photovoltaic panel between a side of the junction box and a plate connected to the junction box by a central fastener; and mounting a spacer adjustable in position in a space between the junction box and the photovoltaic panel.
 15. The method of claim 14, wherein the mounting of the junction box comprises suspending the junction box from the photovoltaic panel.
 16. The method of claim 14, wherein the mounting of the junction box comprises: positioning the side of the junction box in contact with a non-photovoltaic side of the photovoltaic panel; positioning the plate in contact with a photovoltaic side of the photovoltaic panel; and extending the central fastener between the junction box and the plate adjacent and perpendicular to the non-photovoltaic side and non-photovoltaic side.
 17. The method of claim 14, wherein mounting the spacer comprises: mounting a spring loaded spacer between the junction box and the photovoltaic panel.
 18. A method comprising mounting a junction box to four adjacent photovoltaic panels by clamping the four adjacent photovoltaic panels between a side of the junction box and a plate connected to the junction box by a central fastener, the central fastener extending between corners of the four adjacent photovoltaic panels.
 19. The method of claim 18, the mounting of the junction box comprising: positioning the side of the junction box in contact with non-photovoltaic sides of the four adjacent photovoltaic panels; and positioning the plate in contact with photovoltaic sides of the four adjacent photovoltaic panels.
 20. The method of claim 18, wherein the junction box electrically connects the four adjacent photovoltaic panels clamped between the side of the junction box and the plate. 